160105a

Millwright

Grouting Levelling and Anchoring

FIRST PERIOD
Machine Installation and Alignment
© 2019, Northern Alberta Institute of Technology (NAIT) and Southern Alberta Institute of Technology (SAIT). All
Rights Reserved. No part of this publication may be reproduced, stored in or introduced into a retrieval system,
transmitted or communicated in any form or by any means (electronic, mechanical, photocopying, recording or
otherwise) without the prior written permission of the publishers, NAIT and SAIT, except as permitted by law. For
permission requests, please contact: [email protected].

NAIT and NAIT’s logos are registered trademarks of NAIT and may not be used without the prior written permission
of NAIT. SAIT and SAIT’s logos are registered trademarks of SAIT and may not be used without the prior written
permission of SAIT. Other logos, trademarks, registered trademarks and tradenames depicted herein are the
property of their respective owners. Use of them does not imply any affiliation with or endorsement by them. All
reasonable efforts have been made to ensure that this publication is accurate, reliable and free from error at the
time of publication; however, there may be instances where information contained herein is not current. To the
fullest extent permissible under applicable law, NAIT and SAIT disclaim any and all warranties and conditions
respecting this publication, whether expressed, implied, statutory, or otherwise.
 Table of Contents
Objective One ............................................................................................................................................... 2
Basic Levelling Devices............................................................................................................................ 2
Mounting Methods .................................................................................................................................... 9
Layout Procedures................................................................................................................................... 13
Levelling ................................................................................................................................................. 22
Objective Two............................................................................................................................................. 24
Grouting .................................................................................................................................................. 24
Objective Three........................................................................................................................................... 28
Anchor Bolts ........................................................................................................................................... 28
Self-Test ...................................................................................................................................................... 35
Self-Test Answers ....................................................................................................................................... 38
 NOTES
Grouting, Levelling and Anchoring

Rationale
Why is it important for you to learn this skill?
All equipment must be installed, levelled and grouted correctly so that it performs to
design specifications between overhauls. Machines may also require aligning to other
machines so that their shafts are in line with each other. Failure to carry out these tasks
leads to premature equipment failure and unnecessary plant shutdowns.

Outcome
When you have completed this module, you will be able to:
Describe machine levelling, anchoring and grouting procedures.

Objectives
1. Describe levelling tools, equipment and procedures.
2. Describe types, purposes and procedures for grouting.
3. Describe types of anchors and installation procedures.

Introduction
This module addresses how to use basic levelling tools to level industrial machines and
how to use grout between the foundation and a machine bedplate or sole plates.

1
160105ap21.0_updated.docx
NOTES
Objective One
When you have completed this objective, you will be able to:
Describe levelling tools, equipment and procedures.

Basic Levelling Devices

Levelling devices include spirit levels, optical levels and laser levels. A spirit level
consists of one or more level glasses or vials set in a metal or wooden frame. The vial
contains a liquid and an air bubble, whose position in the vial indicates levelness.
Graduations marked on a metal plate at the side of the vial indicate how far out of level a
particular surface is. The sensitivity of the spirit level varies with the type.

Master Precision Level

The master precision level (Figure 1) is the most precise spirit level and should be used
when extreme accuracy is required. Each division is sensitive to within 0.0005 inch per
foot on its main horizontal vial and the level also has an auxiliary transverse vial at right
angles to the main horizontal vial.

Figure 1 - Master precision level.

This is a very sensitive instrument that should be handled with care. It should be picked
up by the top plate only, which does not conduct heat. Allow the instrument to adjust to
the same temperature as the room before using it and do not breathe on the vial, as even
minor temperature changes affect the accuracy of this level. Direct sunshine and drafts of
air should be avoided.

The auxiliary transverse vial is not as sensitive as the main vial. The primary use of the
transverse vial is to check that the level is positioned correctly (on the apex) when
levelling a shaft.

2
160105ap21.0_updated.docx
Precision Level NOTES
The precision level, sometimes referred to as a mechanic's or machinist's level, has a
sensitivity of 0.005 inch per foot per division. It has a longitudinal V-groove in its bottom
surface to enable it to be used to level shafts accurately (Figure 2). These levels are
available in 6-, 12- and 18-inch lengths and may be provided with one or two auxiliary
plumb vials.

Figure 2 - Six-inch mechanic's level.

Bench Level and Carpenter's Level

These levels are not considered accurate enough to level most equipment. For example, a
carpenter's level with a digital readout (Figure 3) can read to an accuracy of only 0.1 of a
degree, which is the equivalent of 0.020 inch per foot.

Figure 3 - Spirit level with digital readout.

3
160105ap21.0_updated.docx
NOTES Plumb Bob
The plumb bob consists of a steel, brass or plastic cylinder with a string passing into one
end. The other end is threaded with a metal cone screwed onto it (Figure 4). By tying the
free end of the string to a bracket mounted to the top of the machine to be checked and
dangling the bob on the end of the string, the side of the machine can be checked for
vertical alignment (plumb).

Figure 4 - Plumb bob.

The point of the cone can also be lined up with reference marks or points scribed in the
floor or baseplate to ensure correct location. One drawback of a plumb bob is that it is
extremely sensitive to drafts and vibration.

4
160105ap21.0_updated.docx
Wire Alignment NOTES
The limitations of a plumb bob can be overcome by using hardened steel piano wire
(typically 0.020 inches diameter) with a heavy weight on the end immersed in a pail of
oil (Figure 5). When performing applications outdoors, the thicker the oil, the better.
Even then, a tarpaulin may be required to shield the wire from wind.

An ohmmeter is connected to the wire and an inside micrometer. The ohmmeter indicates
when the inside micrometer touches the wire and completes the circuit. When the
readings are identical at the top and the bottom, the surface being aligned is vertical.

Figure 5 - Vertical wire alignment.

Two other methods may be used instead of the ohmmeter to indicate when the inside
micrometer touches the wire.
1. A stethoscope on the inside micrometer amplifies the sound of the micrometer
touching the wire.
2. A battery can be used with an electric light bulb, a bell, a buzzer or a headset to
indicate when contact is made.

5
160105ap21.0_updated.docx
NOTES For high or flexible installations where intermediate adjustments can be made, readings
can be taken where necessary between the wire and the vertical surface. Wire alignment
can also be used in a horizontal mode to check the levelness of a machine or base
(Figure 6).

Figure 6 - Horizontal wire alignment.

The wire supports must be adjusted so that the wire is level. The wire is tensioned by
hanging a known weight over a roller at one end. Wire sag charts should be consulted to
determine the amount of sag for the horizontal distance, wire size and tension used
(Table 1).

Table 1 shows typical sag charts for 0.016-inch diameter piano wire with a 30 lb weight
suspended from one end of the wire. The first column shows the distance between
supports for the wire measured in feet. The next five columns show the distance
measured from one support in feet and inches. The sag at that position is measured in
thousandths of an inch.

For example, if the distance between wire supports is 25 feet, the sag in the wire at 4 feet
0 inches from one end is 0.012 inch. At 4 feet 6 inches from the other end, the sag is
0.013 inch. Measure the vertical distance from the wire to the machine surface and add
the amount of sag from the chart to obtain a corrected vertical height. When all corrected
readings are the same, the surface is level. Large machine beds may have sag deliberately
built into them, and this sag has to be compensated for during levelling procedures.

6
160105ap21.0_updated.docx
 Distance From Support Distance From Support Distance From Support
NOTES
Supports

Supports

Supports
Distance

Distance

Distance
Between

Between

Between
Ft 0 in 3 in 6 in 9 in Ft 0 in 3 in 6 in 9 in Ft 0 in 3 in 6 in 9 in

6 0 000 000 000 000 16 4 007 007 007 007 21 4 009 010 010 011
6 1 001 001 001 001 16 5 008 008 008 008 21 5 011 011 012 012
6 2 001 001 001 001 16 6 008 008 009 009 21 6 012 013 013 013
6 3 001 16 7 009 009 009 009 21 7 013 014 014 014
8 0 000 000 000 001 16 8 009 21 8 014 014 015 015
8 1 001 001 001 002 17 0 000 001 001 002 21 9 015 015 015 015
8 2 002 002 002 002 17 1 002 003 003 004 21 10 015 015 015
8 3 002 002 002 002 17 2 004 005 005 005 22 0 000 001 002 002
8 4 002 17 3 006 006 006 007 22 1 003 004 004 005
10 0 000 000 000 001 17 4 007 007 007 008 22 2 006 006 007 007
10 1 001 001 001 002 17 5 008 009 009 009 22 3 008 008 009 009
10 2 002 002 003 003 17 6 009 009 009 010 22 4 010 010 011 011
10 3 003 003 003 003 17 7 010 010 010 010 22 5 012 012 012 013
10 4 003 003 003 003 17 8 010 010 010 22 6 013 014 014 014
10 5 003 18 0 000 001 001 002 22 7 014 015 015 015
12 0 000 000 001 001 18 1 002 003 003 004 22 8 015 016 016 016
12 1 002 002 002 003 18 2 004 005 005 006 22 9 016 016 016 016
12 2 003 003 003 004 18 3 006 007 007 007 22 10 016 017 017 017
12 3 004 004 004 004 18 4 008 008 008 009 22 11 017
12 4 004 005 005 005 18 5 009 009 009 010 23 0 000 001 002 002
12 5 005 005 005 005 18 6 010 010 010 010 23 1 003 004 004 005
12 6 005 18 7 011 011 011 011 23 2 006 007 007 008
13 0 000 000 001 001 18 8 011 011 011 011 23 3 008 009 009 010
13 1 002 002 002 003 18 9 011 23 4 010 011 011 012
13 2 003 003 004 004 19 0 000 001 001 002 23 5 012 013 013 014
13 3 004 004 005 005 19 1 003 003 004 004 23 6 014 014 015 015
13 4 005 005 005 005 19 2 005 005 006 006 23 7 015 016 016 016
13 5 005 006 006 006 19 3 007 007 007 008 23 8 016 017 017 017
13 6 006 006 006 19 4 008 009 009 009 23 9 017 017 018 018
14 0 000 001 001 001 19 5 010 010 010 010 23 10 018 018 018 018
14 1 002 002 003 003 19 6 011 011 011 011 23 11 018 018 018
14 2 003 004 004 004 19 7 012 012 012 012 24 0 000 001 002 002
14 3 005 005 005 005 19 8 012 012 012 012 24 1 003 004 005 005
14 4 006 006 006 006 19 9 012 012 012 24 2 006 007 007 008
14 5 006 006 006 007 20 0 000 001 001 002 24 3 009 009 010 010
14 6 007 007 007 007 20 1 003 003 004 004 24 4 011 012 012 013
14 7 007 20 2 005 006 006 007 24 5 013 014 014 014
15 0 000 001 001 002 20 3 007 008 008 008 24 6 015 015 016 016
15 1 002 002 003 003 20 4 009 009 010 010 24 7 016 017 017 017
15 2 004 004 004 005 20 5 010 011 011 011 24 8 018 018 018 018
15 3 005 005 006 006 20 6 012 012 012 012 24 9 019 019 019 019
15 4 006 006 007 007 20 7 013 013 013 013 24 10 019 019 019 020
15 5 007 007 007 007 20 8 013 013 013 014 24 11 020 020 020 020
15 6 007 008 008 008 20 9 014 014 014 014 24 12 020
15 7 008 008 008 20 10 014 25 0 000 001 002 003
16 0 000 001 001 002 21 0 000 001 001 002 25 1 003 004 005 006
16 1 002 003 003 003 21 1 003 003 004 005 25 2 006 007 008 008
16 2 004 004 005 005 21 2 005 006 006 007 25 3 009 010 011 011
16 3 005 006 006 006 21 3 007 008 008 009 25 4 012 012 013 013

Table 1 - Wire sag chart.

7
160105ap21.0_updated.docx
NOTES Straight Edge
A straight edge is a piece of steel with its edges ground straight. One edge is beveled and
the other is square (Figure 7). A straight edge is used to check surfaces for flatness and
alignment and for laying out straight lines.

CAUTION

A straight edge must retain a smooth edge. Do not drop your straight
edge or nick its edges.

Figure 7 - Straight edge.

8
160105ap21.0_updated.docx
 NOTES
Mounting Methods
Machines that include a driver and driven unit and possibly an intermediate speed
changer usually mount on a common baseplate or skid. Individual units may be mounted
on their own sole plates or on steel supports or floors. Small, lightweight equipment may
have special mounting or levelling feet. Rigid units may be mounted directly on the floor.

Baseplate Mounting
Simple and complex rotating machinery is often assembled on skids or baseplates by
equipment manufacturers and delivered to the industrial end user (Figure 8). Typically,
these skids include pumps or compressors and their drivers, speed changers, receivers,
heat exchangers and lubrication systems. They can be set in place on a foundation and
then levelled, anchored and grouted in place. These separate machines should then be
aligned to each other. Even if the manufacturer has previously aligned the equipment
prior to delivery, the alignment must be rechecked after installation.

Figure 8 - Baseplate mounting.

Sole Plate Mounting

Individual machine units may be set on heavy steel plates that have been either set into
the foundation or mounted on structural steel supports (Figure 9).

Figure 9 - Sole plate mounting.

9
160105ap21.0_updated.docx
NOTES Levelling Feet
Figure 10 shows the various styles of levelling feet available. This type of equipment may
or may not be anchored in place. Small, lightweight equipment is often provided with
levelling feet or levelling screws in the bolting flange on the equipment base (Figure 10A),
similar to those on domestic appliances such as washing machines.

Figure 10 - Levelling feet.

If the machine is to be anchored, one of the arrangements in Figure 10 is normally
employed. The anchor bolt can be situated beside the levelling foot, which can lead to
distortion of the equipment base as the anchor bolts are tightened.

To avoid distortion, the anchor bolt can be installed through the centre of a hollow
levelling foot (Figure 10D) or a levelling nut and a locknut can be used on an anchor bolt
(Figure 10E). Depending upon the weight, the equipment may be installed directly on the
concrete floor or on a concrete pad, which would be thicker than the adjacent floor to
bear the weight.

10
160105ap21.0_updated.docx
Wedges and Shims NOTES
Some equipment is too heavy for levelling feet or it vibrates so much that the levelling
screws would shake loose. Wedges (Figure 11A) and jacking bolts are used to raise
heavy equipment and shims (Figure 11B) are then inserted to support these machines at
the correct elevation.

Apart from the line loading that is imposed on the wedge and the machine, any vibration
may cause the wedge to slowly move out. Consequently, they should not be used to
provide permanent support for the equipment. Shims should be placed under the
equipment, the wedge removed and the shim grouted in place.

Figure 11 - Wedges (A) and shims (B).

Wedges
A wedge is a tapered piece of steel. It should be placed between the base and the
foundation with the flat side down and driven in place with a hammer until the taper
raises the equipment to the point where it is level.

Shims
Shims are pieces of thin, flat steel that range in thickness from 0.001 up to 0.125 inches
for standard shapes and even thicker for homemade shims. They can be cut to any shape
and normally incorporate slots to enable them to fit around the anchor bolt. Pre-cut shims
are made out of stainless steel, but sheet brass and plastic shim stock up to 0.025 inches
thick can be used for lightweight equipment, provided there are no temperature
limitations. Plastic shims are colour-coded for different thicknesses and are easy to cut.
Take care when making your own shims. If they are sheared, ensure they are not
inadvertently bent. Burrs on cut edges should be removed.

11
160105ap21.0_updated.docx
NOTES Vibration Isolators
The unit should not be resting on shims after the grout is placed and set. Some provision
should be made to assure this such as using one long taper shim under the regular shims.
This shim can then be pulled out. Levelling screws should be greased so that they can be
backed off after grout sets. It is important to grease the levelling screws when using
cement-based grout. As the grout dries, it shrinks slightly; the screws can be backed out
so that the unit does not sit only on the shims.

Vibration isolators (Figure 12) prevent vibrations from being transmitted to adjacent
machinery and prevent wear of the machine parts that may occur due to amplification of
the vibration. They may be resilient pads placed under the baseplate or mounting feet,
coil springs or hydraulic or pneumatic shock absorbers.

Figure 12 - Vibration isolators.

12
160105ap21.0_updated.docx
 NOTES
Layout Procedures
Before the new machine or equipment is levelled, it must be located correctly. Depending
upon the size and complexity of the project, the location and its preparation may be the
responsibility of other trades, engineers and surveyors.

Site Preparation
Machines must be installed on a rigid, solid foundation. It may be possible to bolt
lightweight machinery directly to the concrete floor, but heavy, vibrating and
reciprocating machinery requires installation on a much deeper foundation.

The foundation rests on:

• firm ground such as rock, hard clay or compacted gravel (Figure 13A),
• a footing that covers a large area to distribute the weight (Figure 13B) or
• piles (Figure 13C).

Figure 13 - Foundation supports.

Piles
Piles rely on friction between the pile and the ground it contacts to support the weight.
The size, number and depth of the piles depend on the quality of the ground through
which the pile passes and on the weight to be supported.

13
160105ap21.0_updated.docx
NOTES Templates
If anchor bolts are to be installed before the foundation concrete is poured, a template is
required to line up the anchor bolts with holes in the machine base, sole plate, baseplate
or skid. This template is commonly made out of wood (Figure 14). Reference lines have
to be established in order to locate the template properly.

Figure 14 - Wooden template.

Anchor bolts can also be welded to the rebar placed in the foundation. The bolts should
protrude above the foundation height sufficiently in order to allow room for grout,
baseplate thickness and bolt fasteners. Typically, foundations are set ¾ inch to 1½ inches
(19 mm to 38 mm) low to allow for grout.

NOTE

If holes are to be drilled in the foundation after it is poured, reference

lines are required in order to locate the equipment correctly.

14
160105ap21.0_updated.docx
Reference Lines NOTES
Depending upon the industry, main reference lines can also be known as working,
control, lumber, datum or axis lines. The most important reference line is the machine
centreline (Figure 15) with others parallel to the centreline and ones at right angles to the
centreline.

NOTE

Keep the number of reference lines to a minimum to avoid confusion,

and take all-important measurements from the same side of one
reference line only.

Reference lines are established from reference points, datum or centrelines of other
machines for new tie-ins (Figure 15A). Elevations are established from plant and
machinery benchmarks (Figure 15B). Plant datum points are permanent reference points
to which permanent machinery datum are correlated. Datum points often are brass plugs
inserted in machine plates and concrete floors with reference lines scribed on them and
centre-punched.

Figure 15 - Reference lines.

15
160105ap21.0_updated.docx
NOTES Brass plugs for metal plates can be 1/2 inch (13 mm) brass cap screws inserted into a
tapped hole in the plate, cut off and filed flush. Brass plugs for concrete floors are much
bigger, typically 2 inches in diameter (50 mm) and 3 inches deep (76 mm) with grooves
in the sides to allow them to be grouted or glued into the concrete floor.

Reference points can be made permanent with brass plugs or with scribe marks and
centre punching in the concrete or metal surface. Reference lines may be established
temporarily with piano wire, chalk lines, nylon string or soapstone or they can be
permanently scribed into the surface.

Mechanical, optical and laser equipment can be used to establish the position of the
reference points and lines. Right angles can be established by using the 3-4-5 triangle
rule. In a right-angled triangle, the sum of the squares of the two sides containing the
right angle is equal to the square of the hypotenuse (the long diagonal side), such as
32 + 42 = 52 (Figure 16).

Figure 16 - Triangle rule.

16
160105ap21.0_updated.docx
Referring to Figure 16, measure three units along the centreline from the point where the NOTES
right angle is needed (point A) and four units towards the new line. The line BC is
exactly 5 units long. This works for multiples of three, four and five (such as numbers 6,
8 and 10) and, the larger the units are, the more accurate the resulting right angle is.
The right angle can also be established with arcs (Figure 17). Using point A as the centre,
scribe arcs A and B of the same radius. With B and C as centres, scribe equal arcs on the
side where the new square line is required. Lines A to D (where the arcs intersect) are
square to line BAC. The larger the arcs, the more accurate this right angle is.

Figure 17 - Using arcs to establish a right angle.

17
160105ap21.0_updated.docx
NOTES Piano wire and string can be centred above reference marks and marks established from
lines by using a combination square (Figure 18). Some means of moving the line
sideways is required at the hold-down points and the line should be tensioned with
weights or turnbuckles to maintain accuracy.

Figure 18 - Transfer of reference marks.

Once the machine position has been laid out, the site can be excavated if necessary.
Rebar and anchor bolts can then be placed and the foundation can be poured. In the case
of an existing foundation or floor, the anchor bolts are placed.

18
160105ap21.0_updated.docx
Installing Anchor Bolts in Concrete NOTES
Select the anchor bolts to be used, whether expandable or non-expandable. The type of
anchor bolt being installed determines the type of drill. A core drill and bit are used to
drill holes for non-expandable anchors and a rotary hammer drill is used with self-drilling
expansion sleeves.

Safety Considerations
You will produce noise, dust and vibration when you are using a core drill or rotary
hammer drill. Ensure you use proper safety glasses, ear protection, a dust mask, gloves
and normal personal protective equipment (PPE). Ensure that other people working in the
immediate area also have the protection they need.

Self-Drilling Expansion Sleeves

The self-drilling expansion sleeve is used first as the drill for its own hole and then as an
expandable fastener. The size of expansion sleeve depends on the size of bolt required for
the anchoring application. The rotary hammer drill is used as a combined jackhammer
and drill or as a hammer only (Figure 19).

Figure 19 - Rotary hammer drill with self-drilling expansion sleeve.

19
160105ap21.0_updated.docx
NOTES Follow these steps to insert an anchor with a hammer drill.
1. Place the expansion sleeve (cutting sleeve) into the rotary hammer drill chuck
with the tapered expander set aside. The tapered expander is not used for the
drilling process.
2. Select drill and hammer on the selector switch. Proceed to drill the hole. Use
water to cool the cutting sleeve and to keep the dust down. Drill until the shear
point (groove) on the cutting sleeve is just below the surface of the concrete.
3. Remove the drill and cutting sleeve from the hole. Clean any cuttings out of the
hole and clean the cutting sleeve.
4. Insert the tapered expander firmly into the cutting (now expansion) sleeve. Tap it
in if necessary. It must not fall out as the expansion sleeve is installed in the
anchor hole. It is now ready to be hammered into the hole.
5. Select hammer only and reinsert the sleeve into the hole for installation. It must
be kept straight up to avoid breaking the fastener or damaging the concrete.
6. Hammer the fastener into the hole. The tapered expander expands the sleeve,
locking it into place. The shear point should be below the surface. Stop drilling
and lean the drill from one side to the other until the fastener breaks off at the
shear point.
7. Clean any dust or burrs from the new anchor. Insert a bolt into the anchor to be
sure the threads are clean. Sweep up the area. Remove the bolt. Eject and throw
away the broken portion of the expansion sleeve. Clean the rotary hammer drill
and put it away.

20
160105ap21.0_updated.docx
Non-Expandable Anchor Bolts NOTES
A core drill and bit are used to drill holes for non-expandable anchor bolts. When each
anchor bolt is installed in a finished hole, a flat washer is placed over the bolt to centre it
in the hole and cover the grout.

Follow these steps to install a non-expandable anchor bolt.

1. Select a drill bit slightly larger than the diameter of the flat washer used. This
allows the washer to be embedded in the grout flush with the concrete surface.

CAUTION

The same safety considerations apply to the installation of anchor bolts

as to expansion sleeves. Proper safety equipment must be worn.

2. After inspecting the core drill and bit carefully to be sure they are suitable for
use, drill the holes according to the template markings. Keep the drill straight and
upright at all times.
3. Keep the core drill cool with water during the drilling process. This also controls
dust.
4. Drill deep enough to accommodate the length of the selected anchor bolt. The
thickness of the feet on the machine being anchored determines how high the
anchor bolt threads must sit above the concrete surface.
5. Clean all the finished holes. Place the anchor bolt assemblies close to each hole.
6. Prepare the required amount of grout.
7. After placing each fastener in the hole, fill each hole about 3 4 full of grout and
work the bolts up and down to remove any air pockets. Then fill each hole to the
top.
8. Place the washers onto the bolts and work them in so that they are flush with the
concrete surface. Wipe away any excess grout.
9. Check all bolts to be sure they sit straight in the holes at the correct height. Check
alignment according to the template and adjust if necessary. All threads and
shanks must be clean.
10. Rope off the area to prevent traffic and allow time for the grout to set fully.
11. Sweep up the area, clean the core drill and bit and put them away.
12. The machine or baseplate can then be placed over the anchors and is ready for
levelling. Ensure the machine is correctly supported and slings are attached to all
the lifting points provided by the manufacturer.

21
160105ap21.0_updated.docx
NOTES Levelling
The first step of levelling is to check that the level is in adjustment. Place the level on a
machined flat surface that is close to being level in order to check the main vial. Draw an
outline around the level and note the position of the bubble. Turn the level 180° and place
it within the outline. Ensure the bubble is in the same position on the vial. If it is not, the
level requires adjusting (adjust the bubble half way back to the centre position). Repeat
this procedure on a vertical surface to check the auxiliary vial or vials.

Levels normally incorporate an adjusting screw and a locking screw. Loosen the locking
screw before turning the adjusting screw and tighten the locking screw after adjustment.

The surface to be levelled should be clean, smooth, flat and free of burrs and weld
spatter. The level should be placed parallel with the surface being levelled. Most machine
manufacturers specify which surfaces should be used to level the machine. For a flat
surface, establish the correct elevation of the datum point from an adjacent datum point
or benchmark with a precision level. Level all planes from that point (Figure 20).

Figure 20 - Levelling sequence.

If surfaces are warped or sprung, it may be necessary to average out the error to obtain
the best possible levelness to get equal, but opposite readings on either side of a high
spot. If all the exposed machine surfaces are rough castings or irregular, it may be
necessary to disassemble part of the machine to reveal a machined surface in order to
level the whole machine properly.

In order to level a machine surface using a precision level, first determine the ratio
between the length of the surface to be levelled (Figure 21A) and the length of the
precision level (Figure 21B).

Figure 21 - Use of a precision level.

22
160105ap21.0_updated.docx
Either count the number of calibrated graduations on the precision level required to bring NOTES
the instrument level or use feeler gauges, shims or a taper gauge to achieve the same
condition. If this height is G, then the shim adjustment required to bring the machine
surface level is as follows.

A
G
B

Keep the number of shims to a minimum in order to avoid springiness and decrease the
number of surfaces to attract dirt. For any levelling or alignment process, a maximum of
four shims is recommended with a combined thickness of 18 inch (3.2 mm) maximum.

NOTE

Gaps greater than 18" should be filled with a single spacer with a shim
pack on top.

Repeat this procedure across the width of the machine and then, if possible, across the
diagonal while always working from the same starting point. Check the levels all around
after tightening the anchor bolt nuts to 50% of their final torque value. Long and heavy
machines may have intermediate shim points along their lengths and at the corners. As
the machine may have sag deliberately built into it, check these intermediate positions for
levelness and shim. The beds of large engines and the ways of long machine tools must
be level throughout their length and across their width. Once the machine is level, check
against the required elevation. This can be adjusted by adding or removing an equal
number of shims from all shim packs.

Once the skid, baseplate or sole plate has been shimmed and levelled, it can be grouted in
place. After the grout has cured and the anchor bolts torqued to their final value, the
machine itself requires levelling checks carried out in accordance with the machine
manufacturer's instructions.

23
160105ap21.0_updated.docx
NOTES
Objective Two
When you have completed this objective, you will be able to:
Describe types, purposes and procedures for grouting.

Grouting
Grout is a structural connection used to fill the space between the foundation and the
machine. It transfers the compression and vibratory load of the machine evenly to the
foundation and helps maintain precise alignment. Grout can also be used to secure anchor
bolts in a foundation.

Concrete foundations that are to be covered with grout should have their surfaces
roughened up to provide a better bond between the grout and the concrete. Loose material
should be removed. Any concrete with oil-covered areas should have the oily section
chipped out and then grouted at once before the oil has a chance to work to the surface.
To ensure a good bond with cement-based grouts, the old concrete should be thoroughly
dampened until there is no water suction. A thin slurry of cement and water should be
applied just prior to grouting. Any exposed areas of grout should be trowel-finished to
give a good appearance around the machine.

The two main types of grout are:

1. cement-based and
2. polymeric.

Cement-Based Grout
Cement-based grout can be made out of Portland cement. The grout should be so stiff that
it has to be placed and worked into position, not poured. The normal mix for grout up to
four inches thick includes:
• one part cement,
• two parts sand,
• three parts aggregate not over 38 inch diameter and
• only enough water to form a stiff consistency.

Thin grout for filling bolt holes can contain:

• one part cement,
• two parts sand and
• enough water so that the grout can be poured.

The finished grout should be kept wet for 24 hours by the use of sprays or covered with
wet canvas or sacking. Cement-based grout can be worked on after seven days, but
reaches its full compressive strength after 28 days.

Home-made grout mixtures tend to shrink and are slow to cure. Metallic particles can be
added to the mixture to cause oxidation and hence swelling of the grout to offset this
shrinkage. However, this is difficult to control and commercial grout mixtures that
contain non-metallic, shrinkage-compensating expansion agents are preferred. These
mixtures require the addition of water only.

24
160105ap21.0_updated.docx
 NOTES
NOTE

Cement-based grout mixtures should not be placed in temperatures

below 5°C unless auxiliary heating is provided.

DANGER

Grouts containing silica are harmful to the eyes, skin and respiratory
system. Wear eye protection, rubber gloves and dust masks at all times.

Polymeric Grout
These synthetic grouts include epoxy resins and polyurethanes. Polymeric grouts are
supplied with separate packages of resin, hardener and aggregate. These grouts have
many advantages.
• They are non-shrinking.
• They are impervious to moisture, chemicals, corrosion, impact and vibration.
• They have high compressive strengths.
• They have excellent bonding properties.
• They can be applied in cold temperatures (down to -10C).
• They can be put into service less than 16 hours after placing.

Disadvantages are that the synthetic grouts have a shelf life of only one year and a usable
time of only 30 minutes to one hour.

DANGER

When using polymeric grout, wear eye protection, rubber gloves and
dust masks at all times.

25
160105ap21.0_updated.docx
NOTES Grouting Procedures
Before placing any grout, ensure that the machine base, baseplate or sole plate has been
correctly levelled and aligned and that the anchor bolts have been torqued to 50% of their
final value. These bolts are torqued to their final values only after the grout has attained
sufficient compressive strength. Depending upon the mixture used, this could take
between three and seven days.

Formwork is required around the machine base to prevent the grout from slumping until it
sets properly. Figure 22 shows a typical set-up.

Figure 22 - Grouting set-up.

Depending on the size and complexity of the machine base, especially the amount of
room available to place the grout, the grout forms may not be placed until grout has been
packed under the base. No voids or air pockets should remain under the base, as these
may result in stress concentrations. This could lead to the foundation not supporting the
various loads that the machine imposes on it during its operating cycle, especially
additional loads due to start-up or shock. To ensure the greatest accuracy, align and grout
in the same day.

Mix and place the grout in accordance with the supplier's instructions. Pack boxed anchor
bolts with some flexible material in order to prevent the space between the sleeve and the
bolt from filling up with grout. Rods and strapping can be used to tamp the grout into
place. You may need to drill small holes through the baseplate in order to release trapped
air and prevent voids, especially if the grout is very wet or is polymeric.

After the grout has set, tap the baseplate all over to check for voids, which is indicated by
a change in tone. The presence of voids can lead to:
• the baseplate twisting under the load,
• the foundation cracking or
• a condition called soft foot, where the machine's feet do not properly support it.

26
160105ap21.0_updated.docx
If a void is detected, it must be filled. This can be accomplished by drilling and tapping a NOTES
hole for a ¼-inch grease nipple in the baseplate above the void. Drill an adjacent plain
hole (relief hole). Use a grease gun to pump grout through the grease nipple until the
excess grout expels through the relief hole. If a relief hole is not provided, the pressure
exerted by the new grout might lift or distort the baseplate. You can then remove the
grease nipple and seal the hole with grout.

NOTE

The grout used for this operation has to pass through a fairly small hole
in the grease gun, so no aggregate should be used.

Some sole plates and baseplates have counter-bored holes in them through which the
anchor bolts protrude (Figure 23). Once the anchor nuts have been torqued to their final
value, these bolts can be cut off slightly below the surface of the sole plate and the
counterbore can be filled flush with synthetic grout or molten lead.

Figure 23 - Counterbored anchor bolt holes.

27
160105ap21.0_updated.docx
NOTES
Objective Three
When you have completed this objective, you will be able to:
Describe types of anchors and installation procedures.

Anchor Bolts
Anchor bolts attach machines, baseplates and sole plates rigidly to a concrete foundation
or floor. Anchor bolt protrusion must account for grout, machine foot, washer and nut.
Large equipment may require specially designed anchors. Smaller units use commercially
available heavy-duty anchors of various types, including:
• fixed,
• grouted,
• flexible,
• boxed,
• expansion bolt,
• drop-in and
• adhesive.

NOTE

Normal concrete must age for a minimum of 28 days to reach its

maximum compressive strength.

28
160105ap21.0_updated.docx
Fixed Anchor Bolts NOTES
Fixed anchor bolts come in all shapes and sizes, depending upon the machine, foundation
and loading. They can be either a plain round bar with a threaded end or a threaded rod.
Figure 24 shows some of the basic designs.

Figure 24 - Fixed anchor bolts.

Fixed anchors have many disadvantages.
• A template is needed to locate the positions accurately before pouring the
concrete.
• A hoist is needed to lower the machine over the anchors.
• The anchors can easily be misaligned and require subsequent bending to realign
them, which weakens them.
• The threads can easily be damaged.
• The anchors are difficult to replace.

29
160105ap21.0_updated.docx
NOTES Grouted Anchor Bolts
A pocket is left in the concrete foundation so that the anchor can be accurately aligned
without being weakened. Once the machine is in its permanent position, the pocket can
be filled with grout (Figure 25). If there is a significant upward load on the anchor bolt,
the pocket is tapered outwards towards the bottom to provide a wedge-shaped or
pyramid-shaped profile.

Figure 25 - Grouted anchor.

30
160105ap21.0_updated.docx
Flexible Anchor Bolts NOTES
Flexible anchor bolts (Figure 26) are also referred to as pipe anchors or tube anchors. A
pipe set into the concrete allows the anchor bolt inside it to be moved slightly to
accommodate machine alignment. The top opening should be covered with packing waste
to prevent concrete from filling up the pipe whilst the foundation is being poured

Figure 26 - Flexible anchor.

During the final grouting operation, the pipe should also be filled with grout. This
strengthens the anchor bolt and also prevents liquids from filling the hole and possibly
rusting and weakening the bolt.

31
160105ap21.0_updated.docx
NOTES Boxed Anchor Bolts
The boxed anchor is similar to a flexible anchor in that the anchor is installed in the
centre of a pipe or sleeve (Figure 27). It also features a pocket in the concrete pad that
extends through to the side to enable the nut to be removed from the end of the anchor
bolt. This facilitates removal of the anchor bolt in case of breakage, which can happen
when hold-down bolts are subjected to severe vibration.

Figure 27 - Boxed anchor.

Before the concrete foundation is poured, the pipe should be filled with flexible material
to prevent concrete from entering the space. Similarly, when grouting, the space between
the pipe and the anchor bolt should be packed with flexible material.

32
160105ap21.0_updated.docx
Expansion Bolts NOTES
Expansion-type anchor bolts are popular for use on existing concrete floors and pads
(Figure 28). These consist of high-grade steel studs with loose split ring steel wedges
assembled around a waisted, tapered section of the studs.

After drilling a hole in the concrete that is the same diameter as the anchor bolt, the bolt
is hammered into the hole. The washer and nut should first be assembled on the stud
because the hammering usually distorts the last thread. When the nut is screwed down on
the stud, the stud is raised out of the hole slightly, causing the waisted section to move
relative to the wedge, which is jammed against the concrete.

Figure 28 - Expansion bolt.

The taper then expands the wedge into the concrete, causing the whole assembly to be
gripped firmly. One drawback is that, if the machine is moved, it must be lifted to clear
the anchor bolt and afterwards, unless the bolts are sawn or broken off, they constitute a
tripping hazard. This is true of all anchor bolts, apart from the boxed anchors and the
drop-in anchor sleeve.

Drop-In Anchor Sleeves

The drop-in anchor is a sleeve with one end split and the other internally threaded. It is
made out of high-grade steel. It also has an internal expansion plug that is loose and
captive inside the split end of the sleeve (Figure 29). After the hole has been drilled into
the concrete, the sleeve is inserted split end down, and a special setting tool is used to
hammer the plug down inside the sleeve, causing the split ends to expand against the
concrete and grip tightly.

Figure 29 - Drop-in anchor.

A cap screw can then be screwed inside the sleeve to attach the equipment to the floor.
The drop-in anchor has the advantage of not causing a tripping hazard if it is not being
used. It can, however, become full of dirt.

33
160105ap21.0_updated.docx
NOTES Adhesive Anchor Bolts
An adhesive anchor consists of a glass cartridge containing a two-part adhesive mix
(Figure 30). One part is a resin (typically vinyl urethane), and the other is a hardener. One
of these ingredients is contained in a separate glass vial inside the glass cartridge. A hole
is drilled in the concrete and the glass cartridge inserted in it. A rotary hammer drill is
used to drive the anchor bolt into the hole.

Figure 30 - Adhesive anchor.

The anchor bolt has a chisel-shaped mixing end that breaks the glass and mixes the
ingredients. The adhesive mixture then sets within minutes. The cartridge eliminates
mixing errors and wastage, and the glass acts as filler. Adhesive anchors are excellent
where anchors are required near the edge of a concrete foundation or on close centres,
where an expansion anchor could break through the concrete. Quartz sand in the resin
provides reinforcement and prevents creep when the bolt is subject to sustained and
vibratory loads.

NOTE

Plastic capsules can be used instead of glass cartridges. This eliminates

the problem of premature glass breakage, and the plastic dissolves in
the adhesive mix.

34
160105ap21.0_updated.docx
 NOTES
Self-Test
1. Master precision levels should be picked up by the:
a) bottom surface.
b) vials.
c) top plate.
d) sides.

2. A mechanic's level has a sensitivity of:

a) 0.0005 inch per foot per division.
b) 0.001 inch per foot per division.
c) 0.005 inch per foot per division.
d) 0.010 inch per foot per division.

3. You can level machine tools with a carpenter's level.

a) true
b) false

4. Wind can affect both plumb bobs and vertical wires.

a) true
b) false

5. Levelling feet are used on:

a) heavy equipment.
b) large machine tools.
c) small lightweight equipment.
d) vibrating equipment.

6. Which anchor bolt can you replace easily if you break it?
a) fixed
b) flexible
c) drop-in
d) boxed

7. Which anchor is designed to accommodate slight adjustment?

a) fixed
b) flexible
c) expansion bolt
d) drop-in

8. Which anchor is best suited for the edge of a concrete foundation?

a) expansion bolt
b) fixed
c) adhesive
d) drop-in

35
160105ap21.0_updated.docx
NOTES 9. Reference lines are also known as:
a) working lines.
b) control lines.
c) datum lines.
d) all of the above.

10. A 12-inch master precision level requires 0.003 inch of shims under one end to bring
it level when it is placed longitudinally on the bed of a machine tool eight feet long.
What size shim should be placed under the end of the machine tool to level it?
a) 0.002 inch
b) 0.003 inch
c) 0.012 inch
d) 0.024 inch

11. Do not apply grout to a smooth concrete surface.

a) true
b) false

12. Homemade grout mixtures tend to shrink.

a) true
b) false

13. You can place polymeric grouts in colder temperatures than cement-based grouts.
a) true
b) false

14. Before grouting, you should torque anchor bolts:

a) to their final value.
b) to 50% of their final value.
c) to 25% of their final value.
d) not at all until the grout has cured.

15. Grout is so stiff that formwork is not required.

a) true
b) false

16. A master precision level has a sensitivity of:

a) 5 microns per foot per division.
b) 0.0001 inch per foot per division.
c) 0.0005 inch per foot per division.
d) 0.001 inch per foot per division.

17. When using wire sag charts to determine the levelness of a machine bed, deduct the
sag from the measured vertical distance to give the true vertical distance.
a) true
b) false

36
160105ap21.0_updated.docx
18. Because reference lines are all very accurate, you can take important measurements NOTES
from either side of any one of them.
a) true
b) false

19. Do not place cement-based grout mixtures below what temperature?

a) 5C
b) 0C
c) -5C
d) -10C

37
160105ap21.0_updated.docx
NOTES
Self-Test Answers
1. c) top plate.
2. c) 0.005 inch per foot per division.
3. b) false; More accuracy is required.
4. a) true
5. c) small lightweight equipment.
6. d) boxed
7. b) flexible
8. c) adhesive
9. d) all of the above.
10. d) 0.024 inch
11. a) true
12. a) true
13. a) true
14. b) 50% of their final value.
15. b) false; Formwork prevents the grout from slumping until it sets properly.
16. c) 0.0005 inch per foot per division.
17. b) false; Sag is added.
18. b) false; You should take measurements from one side only.
19. a) 5C

38
160105ap21.0_updated.docx
This learning material is the result of a collaborative effort between the Northern
Alberta Institute of Technology, the Southern Alberta Institute of Technology, and the
following Alberta apprenticeship training providers:

Grande Prairie Regional College | Keyano College | Lakeland College

Lethbridge College | Medicine Hat College | Northern Lakes College
Olds College | Portage College | Red Deer College
The Individual Learning Modules Initiative is committed to continuous
updating and is interested in your comments regarding technical accuracy
and clarity of presentation. Please visit our website to register your
comments. To view the ongoing discussion, go to the Bulletin Board:
http://ilm.nait.ca
The Individual Learning Modules Initiative would like to thank the many
individuals and companies for their contribution and gratefully
acknowledges their valuable input.

160105a | Version 21